Engine - Plug-In Hybrid Electric Vehicle (PHEV)
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
|---|---|
| 205-153 (T80T-4000-W) Handle | |
| 300-OTC1819E2, 200# Floor Crane, Fold Away | |
| 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal TKIT-2009TC-F | |
| 303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW | |
| 303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM | |
| 303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM | |
| 303-328 (T88P-6701-B1) Replacer, Rear Seal TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM | |
| 303-465 Tool, Camshaft Align Timing TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 | |
| 303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW | |
| Feeler Gauge | |
| Round-Ended Steel Rule | |
| Piston Ring Compressor |
Materials
| Name | Specification |
|---|---|
| Motorcraft ® Silicone Gasket Remover ZC-30-A | - |
| Motorcraft ® Metal Surface Prep Wipes ZC-31-B | - |
| Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil XO-0W20-QSP | WSS-M2C947-A |
| Motorcraft ® Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 |
| Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A | ESE-M1C171-A |
- 1.NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.NOTE: The front bulkhead does not have an oil squirter.
Torque: 35 lb.in (4 Nm)
- 3.
Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block and install the original main bearing beam bolts finger tight.
- 7.NOTE: Use the original connecting rod cap bolts; installation must keep the same orientation as marked during disassembly or engine damage may occur.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 21 lb.ft (29 Nm)
Stage 3: 90 °
- 8.NOTE: Record the smallest measurement for each connecting rod.
Remove and discard the bolts after measuring.
- 10.
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
- 12.NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.NOTE: The center bulkhead is the thrust bearing.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 13.NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 14.NOTE: Lubricate the journals on the crankshaft with clean engine oil.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 17.NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 18 lb.ft (25 Nm)
Stage 3: 90 °
- 18.
- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- If the crankshaft end play exceeds the specified range, install new parts as necessary.
Distance: 0.01-0.02 in (.22-.45 mm)
- 19.NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 21.NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Use the General Equipment: Piston Ring Compressor
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 22.NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 21 lb.ft (29 Nm)
Stage 3: 90 °
- 23.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC and must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
- 24.
Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
- 25.NOTE: Clean the oil pump and cylinder block mating surfaces.
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 177 lb.in (20 Nm)
- 29.NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.
Clean and inspect all mating surfaces of the engine and oil pan.
Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- 30.NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 34.NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.
Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- 38.NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.NOTE: Lubricate the bolts with clean engine oil prior to installation.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
Torque:
Stage 1: 62 lb.in (7 Nm)
Stage 2: 133 lb.in (15 Nm)
Stage 3: 33 lb.ft (45 Nm)
Stage 4: 90 °
Stage 5: 90 °
- 40.NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance.
Place a paint mark on the crankshaft at the 12 o'clock position.
- 42.NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons.
Using the crankshaft bolt and washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.
- 43.NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 44.
Tighten the camshaft bearing cap bolts one at a time until finger-tightTorque:
Stage 1: 62 lb.in (7 Nm)
Stage 2: 142 lb.in (16 Nm)
- 45.
- 1.
Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet.
- 2.
Use a feeler gauge to measure the clearance of each valve and record its location. Use the General Equipment: Feeler Gauge
- 3.
Repeat to measure all of the lobe/tappet clearances.
- 1.
- 46.NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.NOTE: Select tappets using this formula: tappet thickness = measured clearance + the existing tappet thickness - nominal clearance.NOTE: The nominal clearance is:
- intake: 0.25 mm (0.0095 in).
- exhaust: 0.36 mm (0.0142 in).
NOTE: The acceptable clearances after being fully installed are:- intake: 0.19-0.31 mm (0.007-0.012 in).
- exhaust: 0.30-0.42 mm (0.012-0.017 in).
Select the closest tappet size to the ideal tappet thickness available and mark the installation location.
- 47.NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.NOTE: Mark the location and orientation of each camshaft bearing cap.
Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.
- 49.NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly.
Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-507.
- 50.
If necessary, replace any tappets with the correct tappets selected during the valve clearance check.Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 51.NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 52.NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.
- 53.
Tighten the camshaft bearing cap bolts one at a time until finger-tightTorque:
Stage 1: 62 lb.in (7 Nm)
Stage 2: 142 lb.in (16 Nm)
- 56.NOTE: Before installation, clean and inspect the diamond washer for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.NOTE: The crankshaft sprocket flange must be facing away from the engine block.
Install a diamond washer on both sides of the crankshaft sprocket.
- 63.NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 stepsNOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.
- 66.
Install a holding pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
- 68.NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.NOTE: Use the flats on the camshafts to prevent camshaft rotation.
Torque:
Stage 1: 30 lb.ft (40 Nm)
Stage 2: 60 °
- 69.NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.
Clean and inspect the mounting surfaces of the engine and the front cover.
Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- 70.NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 71.NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.
Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 73.NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.
Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 76.NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
General Equipment: M6 Bolt.
- 77.NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.NOTE: Install a new crankshaft pulley bolt.
Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.
Torque:
Stage 1: 74 lb.ft (100 Nm)
Stage 2: 90 °
- 79.
Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.Torque: 62 lb.in (7 Nm)
- 84.NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
Clean the valve cover gasket surfaces.
Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B
- 85.NOTE: Installation of a new VCT solenoid seal is required if a damaged seal was removed during disassembly of the engine.
Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.
- 88.NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
Torque: 89 lb.in (10 Nm)
- 90.
Apply dielectric compound to the inside of the coil-on-plug boots.Material: Motorcraft ® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)
Torque: 71 lb.in (8 Nm)
- 93.NOTE: The front KS must be installed in the 6 o'clock position and the rear KS must be installed in the 12 o'clock position. The KS must not touch the crankcase vent oil separator.
Torque:
1: 80 lb.in (9 Nm)
2: 89 lb.in (10 Nm)
3: 177 lb.in (20 Nm)
- 94.NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.
- 97.NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
Material: Motorcraft ® SAE 0W-20 Synthetic Blend Motor Oil / XO-0W20-QSP (WSS-M2C947-A)
- 125.NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).
Install the flywheel and new bolts.
- Using a universal pulley holder, tighten the new crankshaft pulley bolts in sequence shown.
Torque:
Stage 1: 37 lb.ft (50 Nm)
Stage 2: 59 lb.ft (80 Nm)
Stage 3: 83 lb.ft (112 Nm)
- Using a universal pulley holder, tighten the new crankshaft pulley bolts in sequence shown.
- 126.
Install the damper and the bolts.- Using a universal pulley holder, tighten 2 turns at a time in sequence shown.
Torque: 21 lb.ft (29 Nm)
- Using a universal pulley holder, tighten 2 turns at a time in sequence shown.